Power Solutions Case Studies

Westermost Rough 275/132kV Harmonic Filters - 2014

Project Description:
In 2014, Powell Engineering UK Limited (PEL) was successfully awarded the contract by Alstom to install two Harmonic Filters (1 x 150kV HF, 1 x 275kV HF) and one 275kV HF AIS Feeder Bay for the Westermost Rough Windfarm Onshore Substation for Dong Energy.
The substation connects DONG Energy’s Offshore Wind Farm to the UK’s transmission system. The Westermost Rough Offshore Wind Farm's site is situated 8km off the Yorkshire Coast, north of Hull and contains 35 turbines of 6MW capacity, covering a total area of 35km2 providing enough electricity to power around 200,000 homes. It helps to fulfil the UK's commitment to reducing CO2 emissions and contribute towards the UK achieving its targets of electricity generation from renewable energy schemes.

PEL were responsible for the installation of all main plant and equipment associated with the two Harmonic Filter bays and Feeder bay including:

  • Capacitor Banks
  • Reactors and sound shields
  • Resistors
  • Disconnectors with double Earth switches
  • Surge arrestors
  • Current Transformers
  • Earth Switches
  • Post Insulators
  • Support Structures
  • Busbars, Conductors and connectors
  • Marshalling kiosks
  • Power, control and signalling cabling works associated with the new equipment
  • Earthing
  • Interlocking system

    PEL were challenged by numerous issues ranging from adverse weather conditions to late design changes. A delayed start lead to an extremely demanding programme coupled with having to work in parallel with other contractors in a relatively enclosed area. Efficient operational planning with Alstom, DONG and the other contractors on site was key to the success of the project.
    Site operatives showed a persistent determination to overcome every difficulty and challenge and through genuine operational team work we delivered the project safely, on time and to budget. This commitment to both efficiency and safety developed a cooperative and professional working relationship with Alstom and DONG which in turn enabled us to deliver value to our client.
    The PEL stores and fabrication workshop provided invaluable support and enabled PEL to react effectively and efficiently to expedite changing site designs and demands.

    In July 2014 the completed Harmonic Filter and Feeder bays were successfully handed over to our client.

  • Sellindge 400kV AC-DC Convertor Station
    2009-2014

    Project Description:
    Powell Engineering UK Limited (PEL) have worked with Alstom Grid to completly renovate the UK end of the world’s highest rated submarine High Voltage Direct Current link with France
    The original 400,000 Volt interconnection consisted of plant and equipment designed specifically for this facility being the only one of its kind in the world and consists of two 1,000 Mega Watt Bipoles providing an impressive 2,000 Mega Watt capacity of power transfer.

    What we were Asked to Do
    PEL were challenged with the complete dismantlement and replacement of the existing equipment in two distinct phases, allowing one Bipole to remain in service maintaining an operational link with France. In addition, PEL were asked to complete each of the two Bipole refurbishment installations in just 28 days.
    This extremely demanding timescale required PEL to analyse and meticulously plan every operation, innovating techniques to minimise the time for every operation in order to meet these extremely tight deadlines.

    How we did it
    The key to our success was both efficiency and safety, delivering value to our client. Existing valve module dismantlement methods proved to take too long given the short timescales, so PEL designed and developed new equipment to speedily remove the 1,000 valve modules from the stacks. Cutting edge compact cranes were employed to operate in the confined Valve Halls. Both day and night shifts worked tirelessly to a detailed integrated programme comprising a diverse range of engineering disciplines including structural and mechanical design, cooling and HVAC system installation, control panel, wiring and cable installation together with new floor mounted HVDC thyristor valve installation. In excess of 200,000 man-hours were worked by PEL with only one injury, reflecting an outstanding safety performance.

    What Delivered the Success
    Genuine operational teamwork together with a relentless determination to overcome every difficulty and challenge proved to deliver our goal. We forged a professional and cooperative relationship based on trust and commitment with both Alstom our client and the end user National Grid
    Being prepared to do more than that ordinarily expected, secured the success in PEL meeting the challenging programme deadlines for the project. Phase 1 Outage for Bipole 1 was completed in May 2011 followed by the conclusion of Phase 2, Bipole 2 in May 2012
    The meticulous detailed knowledge and cooperation from Tim Brooker’s team on site together with the leadership from Stephen Mart of National Grid and Alstom was critical to the completion of the project and the management of the refurbishment works whilst maintaining an operational Bipole throughout the project. In addition, PEL provided important support with the cabling installation at Les Mandarins in order to expedite overall completion of the refurbishment.
    The experience of the Phase 1 works proved to be invaluable in the preparation for the Phase 2 operation. Refined waste removal methods and installation programming together with an optimised management structure demonstrated an even higher level of operational efficiency through Phase 2 of the works.

    The combined dedication from everyone at National Grid, Alstom and Powell Engineering UK Ltd., delivered the refurbishment of the Sellindge Converter Station safely and successfully.

    Stoke Bardolph 400kV AIS Substation - 2013

    The Challenge

    To install a new air insulated Grid Supply Point at Stoke Bardolph, near Nottingham, including the associated remote end modification works at both High Marnham and Ratcliffe on Soar. These works formed the electrical and mechanical installation element (2013) of a £30m 400/132kV substation for National Grid and Central Networks.

    The Requirement

    This project presented the opportunity for PEL to demonstrate their ability to deliver a high quality service, to both a specified programme and high industry safety standards for ABB and the Electrical Alliance Central. Key areas of equipment installation included busbars and lines, surge arrestors, disconnectors, earth switches, voltage and current measurement, together with all associated insulators and equipment structures. In addition, PEL supplied and installed all associated substation multicore field cabling to prefabricated relay rooms. The 400kV equipment serves two new 240MVA, 400/132kV SGTs.

    The Outcome

    The installation was completed in accordance with ABB’s programme despite severe weather conditions and nesting birds. These works were undertaken safely and essentially accident free. Both ABB and National Grid acknowledged the excellent standard of the PEL workforce and delivery team.

    The Success Factors

    Early detailed operational planning with the Project and Site Manager proved invaluable in the ongoing success of a site team which enjoyed good discipline led by an experienced Site Supervisor and high working morale. Regular detailed attention to programme, quality and finance in close partnership with ABB delivered joint success. PEL demonstrated their ability to react quickly and efficiently to challenging project demands; from Head Office stores supply to site through to adapted resource deployment, mitigating risk and delivering exceptional value. The working relationship between ABB and PEL has been strengthened in preparation for future works in true partnership.

    Phil Worrall – Project Manager

    “Acknowledging the added industry challenge of RIIO, my intention is to deliver true sustainable value. This project achieved this through planning, genuine team work, respect and cooperation with all involved. In addition, the whole team enjoyed a positive work experience.”

    Alun Robinson - NG Project Manager

    "National Grid have recently completed a multi-million pound new substation project at Stoke Bardolf and Powell Engineering were the chosen M&E installation contractor for this site. Powell Engineering came onto this site towards the end of the civil phase and instantly became part of the overall site family team. During the project I always found Powell Engineering's work to be of the highest standard which was further underlined by their excellent attitude to safety, co-ordination and flexibility. I wish them all the success in any further ventures with National Grid."

    Hyde 132kV AIS Substation - 2013

    Project Description:
    In June 2013 Powell Engineering were awarded the first stage of a 132 kV project for Electricity North West (ENW). In conjunction with the replacement of 132 kV Grid Transformers, PEL were responsible for the installation of associated plant and equipment
    Our remit was:

  • Removal of redundant structures and apparatus
  • Installation of new support structures and aluminium gantries
  • Erection and installation of secondary equipment, HV conductors and connectors
  • Installation of Protection Panels, cabling, relay and pilot modifications
  • 33kV switchgear terminations
  • 33kV circuit breaker CT change This would entail;
  • Project and ENW authorised Site Management
  • Receiving safety documents (Permit to work and LOA)
  • Installation of all free issued materials
  • Procurement of all earthing and multicores
  • Removal and transfer of redundant equipment
  • Installation of secondary equipment, cabling and protection work

  • The refurbishment works was undertaken with limited space within a compact compound, adjacent live circuits and 132kV overhead lines. Independent contractors were also present working in parallel to our works. It was essential to build a close working relationship with these contractors to ensure a safe and efficient working environment.
    Intricate planning and financial control meant that a smooth cash flow was maintained throughout. All aspects of management for the project including, procurement, HS&E and Quality control was run from our Doncaster Office. Throughout the works and on completion of the project Powell Engineering received excellent feedback from the client acknowledging our excellent health & safety performance along with high standards and quality of the workmanship.

    We have recently been awarded stage two of the project which is due to commence early 2014

    Hutton 400kV Thyristor Controlled Series Compensation

    Project Description:
    ABB selected Powell Engineering UK Ltd (PEL) to carry out the installation of their TCSC (thyristor controlled series compensation) equipment for Hutton substation in the first UK installation of its type.
    This is a major FACTS (Flexible Alternating Current Transmission System) project by National Grid to boost the flow of electricity from Scotland to England. Working closely with ABB who in turn operate as part of National Grid’s Electricity Alliance Central (EAC), PEL have successfully installed the innovative and cutting edge design TCSC equipment at the Hutton 400 kV substation near Kendal in Cumbria.
    This exciting project is part of National Grid’s strategy for the electricity transmission network to achieve the national target of 15% of the UK’s energy to be produced from renewable energy sources by 2020. This series compensation equipment improves power system stability and allows more power to be transferred through existing circuits. It uses thyristor control to increase the flow of power, mitigate SSR (subsynchronous resonance) and to ensure stability in the power supply grid system.

    What we were Asked to Do
    PEL were challenged with the reception, offloading and complete installation of the TSCS equipment together with associated cabling and fibre optic works. An extremely demanding timescale required PEL to work closely with ABB and their EAC partners to meet overall project key milestones safely.This required working alongside and simultaneously with the EAC civil engineering site team to avoid costly delays.
    We were required to analyse and meticulously plan our operation. PEL utilised innovating techniques to optimise operational performance in order to meet the overall project deadlines.
    Key areas of equipment installation included:

  • busbars
  • surge arrestors
  • reactors
  • earth switches
  • voltage and current optical measurement, together with all associated insulators and equipment structures.

  • In addition, PEL supplied and installed all associated substation multicore field cabling to prefabricated relay rooms.

    How we did it
    Our success was a direct result of efficient operational planning and safety. This in turn delivered value to ABB. PEL are committed to ever closer collaboration with its clients as this demonstrates efficiency and increased value through the supply chain.
    A willingness to operate extended working and weekend working provided for acceleration when required. PEL provided a diverse skill set across the site operation from TCSC platform assembly with tandem crane lift erection and HV equipment installation through to pumping plant cooling system installation.
    Where shortages or equipment problems were encountered, PEL where possible provided either a manufactured solution or procured items within extremely short timescales. Some 27,000 man-hours were worked by PEL with no injury. This demonstrates our outstanding safety performance.

    What Delivered the Success
    The key elements which delivered success include early detailed operational planning with a structured operational team working closely together with all parties.
    The combination of a proficient and dedicated Site Manager together with an experienced Site Supervisor proved invaluable in the ongoing success of the site team. Maintaining a high morale and a commitment and determination to overcome difficulties delivered success. We continued and developed a cooperative and professional relationship based on mutual trust and commitment with ABB.
    PEL again demonstrated that we are prepared to do more than that ordinarily expected and have further strengthened our relationship with ABB for future opportunities in genuine partnership.

    On Reflection
    TCSC Equipment at Hutton comprised two identical three phase circuits namely Harker 1 and Harker 2. The experience of the installation of every element allowed PEL to refine their installation techniques for the second circuit. This clearly delivered operational efficiency as the works progressed. The combined dedication from everyone at National Grid, ABB and Powell Engineering UK Ltd., delivered the first TCSC installation in the UK at Hutton safely and successfully.

    Phil Worrall – Project Manager
    “Delivering value is the key to our ongoing success as part of the industry challenge of RIIO. We succeeded at Hutton through genuine team work, careful planning and the respect and cooperation of all involved. Our team maintained a positive attitude and a safe working culture.”

    Harestanes Windfarm 33/132kV Substation - 2013

    Project Description:
    2013 has seen Powell Engineering undertake its inaugural project for Iberdrola/SPEN. The £160 million Harestanes windfarm project provides renewable electricity in Dumfries and Galloway. In partnership with Iberdrola, the world’s largest wind energy developer, PEL have made a major contribution in the successful installation of this sustainable energy project.

    To facilitate the connection of renewable generation in southern Scotland, PEL were contracted to construct a new 33/132kV AIS substation to connect a new windfarm development to the national grid. Harestanes 33/132kV substation consists of two 90MVA grid transformer circuits Grid T1A and Grid T1 B supplied by one incoming feeder bay with the 132kV grid in-feed from Moffat 132/400kV grid substation along with two dedicated 33kV circuits connecting the windfarm substation.
    Excluding the grid and auxiliary transformers, PEL were responsible for the installation, testing and commissioning of all plant. PEL were also responsible for the supply of post insulators, NERs, clamps and conductors, power and multicore cables, mechanical and electrical interlocking, compound floodlighting and computer raised flooring. All 132kV and 33kV support structures were manufactured and supplied from PEL fabrication workshop. This proved invaluable as PEL were able to react effectively and efficiently to expedite changing site designs and demands.
    PEL were challenged by numerous issues ranging from adverse weather conditions to late design changes to support structures. Site operatives showed a persistent determination to overcome every difficulty and challenge and through genuine operational team work we delivered the project safely, on time and to budget. This commitment to both efficiency and safety developed a cooperative and professional working relationship with Iberdrola/Scottish Power which in turn enabled us to deliver value to our client

    In September 2013 the completed Harestanes 33/132kV substation was handed to our client operational, fully commissioned complete with records and “As built” drawings.

    Carrington 400kV GIS/GIB - 2013

    Project Description:
    In May 2013 PEL were successful in being awarded the Contract by ABB for the installation of the new extension of gas insulated switchgear and bus bars at Carrington 400kV substation near Manchester. The works included the installation of 7 additional 3 phase bays of gas insulated switchgear, associated gas insulated bus bars and the turn in of the 400kV Penwortham – Carrington – Daines circuit to the Carrington 400kV GIS substation.
    These works comprised the following as undertaken by PEL:

  • GIB and GIS Installation
  • 400kV AIS Installation
  • Control and Protection – Control Panel Installation
  • Interlocking
  • Off Loading of All Equipment
  • Above Ground Earthing
  • Provision of cabling and cable management
  • Gassing and Degassing works
  • Commissioning Assistance
  • Site Supervision / Management and HO Project Management

    PEL started on site in June 2013 and carried out the following in the completion of the works:

  • The provision of all installation plant and temporary equipment
  • Installation of control panels and multicore cabling
  • Installation of steel equipment support structures
  • Unpacking and installation of ABB factory manufactured gas insulated equipment
  • Cleaning and installation of this equipment in clean conditions to achieve a gas tight installation.
  • Gassing up and degassing and storing of SF6 gas.
  • Building and maneuvering of test equipment.

    The Outcome
    The installation was completed in accordance with ABB’s programme despite challenging industry conditions. These works were undertaken safely and essentially accident free. Both ABB and National Grid confirmed their acknowledgement of the excellent standard of the PEL quality of workmanship and the attitude of the workforce and delivery team.

    The Success Factors
    Early detailed operational planning and preparations with the Project and Site Manager demonstrated exceptional value. This was clearly seen in the continued success of a site team which displayed discipline and good morale led by a proficient Site Manager and experienced Supervisor. Regular detailed attention to the installation programme, quality and finance in close partnership with ABB delivered joint success.
    PEL demonstrated their ability to react quickly and efficiently to challenging project demands; from Head Office stores supply to site through to adapted resource deployment, mitigating risk and delivering exceptional value. The established professional working relationship between ABB and PEL has been further strengthened in readiness for future exciting works in genuine partnership.

    Phil Worrall – Project Manager
    “Value, safety and trust are at the core of our operation and my intention is to deliver these to each and every project. Carrington was a resounding success through planning, the PEL CAPS system, genuine team work, respect and cooperation with all involved. In addition, the whole team enjoyed a positive work experience.”

    Dave Long – Site Manager
    “When we started this project, the ABB site team had concerns about what PEL could deliver as this was our 1st ABB GIS. I can honestly say these concerns were short lived and now the works are essentially complete, we have established ourselves as ABB’s 1st choice contractor. It is a great pleasure to hear from ABB’s management, National Grid’s SAP’s and CIE, how pleased they are with the standard of workmanship, health and safety awareness and the general attitude of all PEL staff that have been involved on this project. I’d like to take this opportunity to thank all the lads who have contributed to making this project a success as we wouldn’t be where we are without their good work.Thank you.”